Process for preparing metal zeolite catalyst compositions

ABSTRACT

In order to increase the amount of catalytic metal which can be incorporated in a zeolite catalyst by contact of zeolite with solution of a given amount of chemical containing the catalytic metal, or conversely to reduce the amount of such chemical needed to incorporate a given desired amount of catalytic metal in the catalyst, a zeolite containing a cation, e.g., sodium, replaceable by ammonium ion, is contacted with an aqueous solution of ammonium metalate, e.g., molybdate, and a second ammonium compound, e.g., ammonium chloride, said second ammonium compound providing additional anion for balancing the change of said cation in the solution.

United States Patent Potts et al.

PROCESS FOR PREPARING METAL ZEOLITE CATALYST COMPOSITIONS Inventors: John D. Potts, Springfield; Francis William Kirsch, Wayne, both of Pa.

Sun Research and Development Co., Philadelphia, Pa.

Filed: Aug. 23, 1972 Appl. No.: 283,254

Assignee:

References Cited UNITED STATES PATENTS 8/1970 Hansford 252/455 Z 11/1971 Oettinger et al. 252/455 Z 9/1972 Bittner 252/455 2 Dec. 10, 1974 Primary Examiner-C. Dees Attorney, Agent, or Firm-George L. Church; Donald R. Johnson; Anthony J. Dixon [5 7] ABSTRACT In order to increase the amount of catalytic metal which can be incorporated in a zeolite catalyst by contact of zeolite with solution of a given amount of chemical containing the catalytic metal, or conversely to reduce the amount of such chemical needed to incorporate a given desired amount of catalytic metal in the catalyst, a zeolite containing a cation, e.g., sodium, replaceable by ammonium ion, is contacted with an aqueous solution of ammonium metalate, e.g., molybdate, and a second ammonium compound, e.g., ammonium chloride, said second ammonium compound providing additional anion for balancing the change of said cation in the solution.

7 Claims, No Drawings PROCESS FOR PREPARING METAL ZEOLITE CATALYST COMPOSITIONS BACKGROUND OF THE INVENTION The present invention relates to a technique for pre- 5 paring metal catalyst compositions for use in petroleum conversion reactions wherein a crystalline zeolite catalyst support is treated simultaneously with ammonium metalate containing catalytic metal in the anion thereof, and a soluble ammonium compound of a sec- 0nd anion resulting in the formation of a catalytically active composite of the metal and the catalyst base.

It has been known in the art to deposit a metal onto a crystalline zeolite base by simple precipitation techniques.

into a crystalline zeolite catalyst base. This method comprises treating the catalyst with an aqueous solution containing complex watersoluble metalammonium ions which ion exchange with the cations normally present in the zeolite.

Van Helden et al in US. Pat. No. 3,442,794, issued May 6, 1969, disclose a pretreatment of the zeolite base with an acid and with an ammonium compound separately prior to ion exchange of the catalyst base with a metal cation in solution, to prepare an improved hydrogenation catalyst.

SUMMARY OF THE INVENTION Although the catalyst preparation discussed above show good results, a more efficient catalyst preparation technique has now been found which results in increased amounts of metal being deposited onto a catalyst base.

The catalyst bases used for the purpose of the invention are molecular sieve zeolites. The basic formula for these catalysts is as follows:

In the formula M represents a metal of valence n. Different types of sieves are primarily characterized by a definite range of values of x and y and by a particular x-ray powder difiraction pattern. The X-type zeolite, which is the base catalyst used in the specific embodiment of the present invention, has the desired structure and can serve as the base catalyst for the work to be discussed.

The molecular sieve is contacted with an ammonium metalate solution which contains an additional soluble ammonium compound in such an amount that the ammonium ion concentration of the added ammonium compound is preferably essentially equivalent to the ammonium ion concentration of the ammonium metalate in the solution. However, any substantial amount NH, compound of second anion will give the benefits of invention to some extent. This procedure markedly increases the amount of metal retained by the catalyst base. Merely exchanging the sieve with an ammonium compound prior to treatment with the ammonium metal, as is taught in the prior art, does not result in as large an amount of the metal being retained by the catalyst as in the simultaneous procedure of the present invention.

As noted subsequently, the function of the second NH compound is apparently to provide additional anion for charge balancing of Na ion entering the solu tion from the catalyst thereby making available, for incorporation in the zeolite, metalate ion which would otherwise charge balance the Na ion and be held in solution. Any organic or inorganic anion capable of so functioning in the medium of ion exchange can be employed as the second NH compound used. Examples are fluoride, chloride, bromide, iodide, carbonate, bicarbonate, sulfate, phosphate, sulfide, thiocyanate, dithiocarbonate, peroxysulfate, acetate, hydroxide, benzoate, carbonate, citrate, nitrate, nitrite, formate, propionate, lactate, malonate, oxalate, tartrate and the like.

Preference is given to the simple inorganic ammonium compounds, notably NH, compounds such as NH CI, NH NO NH. sulfates, NH phosphates, etc.

Treatment with the mixed solution can vary over a temperature range of ambient to 212F. with a range of to F. being preferred. The pressure may also vary over a broad range; however, it is preferred that this treatment be effected at or near atmospheric pressure.

The following explanation is offered for the preparative technique of the invention, but it is not intended to be limiting of the procedure disclosed herein.

The use of the ammonium metalate salt for treatment of a sodium form Type-X zeolite may be represented as: M...

NaX NI-L, M NH X Na M where M is a metalate ion, i.e., an ion containing catalytic metal. Metalate anion is to be incorporated with the zeolite support by sorption and left in the residue on the zeolite when solvent (water) has been removed. However, the cation or counterion of the metalate, NH in the case at hand, will also remove Na+ from the zeolite by exchange. Na+ removal may be an objective, too. Much if not all, of that Na+ will go into solution when exchanged by NI-I Unless additional anion is present, metalate will remain in solution to counterbalance Na+. That is not undesirable if Na+ removal is the only goal. That is undesirable if sorption of metalate anion on the zeolite is another goal or is the chief goal. The inclusion of an ammonium compound, for example ammonium chloride, provides an anion to balance the Na which enters the solution. The ammonium chloride would then enable a deeper Na exchange to be made by providing a more readily available counter-ion for Na and thereby allow the M anion to be sorbed more readily by the zeolite without resorting to time consuming multiple exchanges and impregnations.

Another desirable feature of the invention is the addition of larger amounts of impregnated metal to an already exchanged zeolite.

EXAMPLE I readily commercially available type of catalyst base.

1. ln the first method, 150 grams of Na Type-X catalyst was treated with a molybdenum solution comprising 24.48 grams of (NH Mo O .4H O in 1,200 milliliters of water. The dried catalyst was added in small Comparing Catalyst 4 to Catalyst 2 shows the substantial increase of molybdenum addition in the inventive procedure used to prepare Catalyst 4. Also, Catalyst 4 contains more than twice the amount of Na of increments to the solution at l50F while continually the stepwise procedure of Catalyst 3.

stirring the solution. The stirring continues for 24 hours at 150F, after which the solution is filtered and the cat- EXAMPLE n alyst separated. The catalyst is then dried for 16 hours In the following set of tests, the base catalyst was first at 125C exchanged with a cobalt solution which results in Cata- 2. Catalyst 2 was prepared by a procedure similar to lo lyst 5. The procedure used was similar to that used in Catalyst 1 except that 36.72 grams of (NH Mo O .4- the Catalyst 3A preparation except with a cobalt solu- H O in 900 milliliters of water was used as the preparation substituted for the ammonium chloride solution tive solution. This amount is equivalent to double the used in the Catalyst 3A preparation. concentration used for Catalyst 1. This b ta] t m t 3. The third catalyst was prepared in a more adl5 lowin Co a yS was Subjec ed to the fol 4 g preparative techmques. vanced method discussed by the prior art; that ts, pretreatment of the catalyst base with an ammonium chlolv Treatment with a m lyb n m SO UtiOH with 05x ride solution and subsequent treatment with the metal relative M0 concentration in a Catalyst 1 p r solution. 2. Treatment with a 2.0): relative concentration of The first step of this procedure, the exchange step, M0 Solution in a Catalyst 2 Procedure and comprises adding 200 grams of the Na-form X-zeolite Simultaneous g -impregnation with a 10x to 600 milliliters of an ammonium hl rid S l ti concentration of Mo solution in the invention preparaprepared by adding 300 grams of Nl-{ Cl to 1,000 millilive que O the Catalyst 4 procedure. liters of water. This mixture is stirred for 30 minutes at The three talysts prepared are designated Catalyst 80C and filtered; and, the wet catalyst Cake is then C y 7 d Catalyst respectively, f r the puradded to the remaining 400 milliliters of the NH Cl soposes of comparison and discussion below- Relative Mo Amount Nl'LCl in in Weight Catalyst Solution Solution Na Co Mo N 6 0.5x NO 6.17 6.35 0.82 0.45

7 2.0x No 5.42 6.40 3.77 1.49

s l.0x Yes 5.03 6.53 4.58 2.46

lution, stirred for minutes at 80C and filtered again. The above data again indicate that inclusion of This exchange of the wet catalyst cake is repeated three NH4C] in e ammonium m y dat Solution esu ts n additional times, resulting in a total of four exposures 40 a catalyst with a larger amount of molybdenum. The of the catalyst to the NH Cl solution. The final sepaabove t also Shows h t h n en i n pro edure rated catalyst is washed with distilled water until chlopreferentially ha g ual Na f m the initially ride free and dried for 16 hours at 125C. This interme- C0 exchanged catalyst Tether than back exchangmg diate catalyst is designated 3A for the purposes of ammomunfl ion for latter discussion and comparison. Compaflng Catalyst 8 to y 7 shows the Catalyst 3A is then treated as described in l above five pl'omdure to be m effective f one half as to produce C l 3 much M0 in the solution, and comparison of Catalyst (4) The inventive procedure was used to prepare 8 to catajlfst 6 Shows h F Y Pro;edure to be Catalyst 4 over five times as effective with JUSI double the Mo To 150 grams of the Na-form X zeolite, a molybdeconcemmuon num solution comprising 36.72 grams (Ni-10 M0 0 Catalyst 4, prepared by the novel procedure of this 4H O plus 22.7 grams NH Cl in 900 milliliters of H 0 invention, has use in petroleum conversion reactions was added in small increments at 150F while stirring. such as hydrodecolorization of lubricating oils, as The stirring continued for 24 hours at 150F at which shown in Example 3 below. time the solution was filtered, the catalyst separated and dried at C for 16 hours. EXAMPLE The metals levels of the four final catalysts and one An 18.2 APU60 gra ity ubricating oil boiling in intermediate catalyst are compared below to the base the range of 700 to 950F was subjected to a high prescatalyst used: sure fixed-bed hydrodecolorization reaction using Cat- Relative Mo Amount Nl hCl Catalyst Solh tion Solir iion Na. Wt% Mo, Wt% N. Wt%

Base yp 14.24

1 IX") N6 12.19 1.96 0 54 2 21" No 12.31 2.38 3A Yes 269 3.66 3 rid" No 2.68 1.23 3.58 4 2e" Yes 702 3.45 3.62

"1 is the amount of molybdenum in the solution used in preparation ot'Catalysl alyst 4 as prepared above. Conditions for the process were as follows:

Temperature 640F Pressure 1000 psig Time on Stream 22.5 hours Catalyst Type 4 Hydrogen l.l

SCFH/V The charge stock had an original ASTM D-l500 color of 5.50 and an ASTM D-l500 color after the above process of 2.00 initial and 2.75 aged, showing the utility of Catalyst 4.

The above hydrodecolorization example shows substantial activity in a catalyst prepared according to the process of the invention, although the amount of molybdenum in the catalyst of the example is not necessarily the optimum for the process involved. Determination of such optimum is within the ability of a person slgilledin the art in the light of the present disclosure.

The process of the invention enables a greater amount of catalytic metal to be incorporated in a zeolite catalyst by contact of zeolite with solution of a given amount of chemical containing the catalytic metal, and therefore makes possible the reduction of the amount of such chemical needed to incorporate a given desired amount of catalytic metal in the catalyst. The amount of chemical needed to obtain a particular desired amount of catalytic metal in the catalyst and the optimum composition of the treating solution to obtain such amount can again be determined by a person skilled in the art in the light of the present disclosure.

We claim as our invention:

1. A process for preparing catalysts which comprises contacting a crystalline zeolite base, containing cation replaceable by ammonium ion, with an aqueous solution consisting essentially of an ammonium metal compound containing catalytic metal in the anion thereof, and a non-metallic soluble ammonium salt.

2. The process of claim 1 wherein the ammonium ion concentration in the aqueous solution due to said nonmetallic soluble ammonium salt is essentially equivalent to the ammonium ion concentration in the aqueous solution due to said ammonium metal compound.

3. The process of claim 1 wherein the non-metallic soluble ammonium salt is ammonium chloride.

4. The process of claim 1 wherein the crystalline zeolite base is a sodium form zeolite X molecular sieve.

5. The process of claim 1 wherein the ammonium metal compound is ammonium molybdate, the soluble ammonium salt is ammonium chloride, the crystalline zeolite base is a sodium form zeolite X molecular sieve and the ammonium ion concentration in the aqueous solution due to the ammonium chloride is essentially equivalent to the ammonium ion concentration in the aqueous solution due to the ammonium molybdate.

6. The process of claim 5 wherein the crystalline zeolite base has been previously ion-exchanged with a first metal different than the second metal used in the ammonium metal compound.

7. The process of claim 6 wherein said first metal is cobalt and said second metal is molybdenum. 

1. A PROCESS FOR PREPARING CATALYSTS WHICH COMPRISES CONTACTING A CRYSTALLINE ZEOLITE BASE, CONTAINING CATION REPLACEABLE BY AMMONIUM ION, WITH AN AQUEOUS SOLUTION CONSISTING ESSENTIALLY OF AN AMMONIUM METAL COMPOUND CONTAINING CATALYTIC METAL IN THE ANION THEREOF, AND A NON-METALLIC SOLUBLE AMMONIUM SALT.
 2. The process of claim 1 wherein the ammonium ion concentration in the aqueous solution due to said non-metallic soluble ammonium salt is essentially equivalent to the ammonium ion concentration in the aqueous solution due to said ammonium metal compound.
 3. The process of claim 1 wherein the non-metallic soluble ammonium salt is ammonium chloride.
 4. The process of claim 1 wherein the crystalline zeolite base is a sodium form zeolite X molecular sieve.
 5. The process of claim 1 wherein the ammonium metal compound is ammonium molybdate, the soluble ammonium salt is ammonium chloride, the crystalline zeolite base is a sodium form zeolite X molecular sieve and the ammonium ion concentration in the aqueous solution due to the ammonium chloride is essentially equivalent to the ammonium ion concentration in the aqueous solution due to the ammonium molybdate.
 6. The process of claim 5 wherein the crystalline zeolite base has been previously ion-exchanged with a first metal different than the second metal used in the ammonium metal compound.
 7. The process of claim 6 wherein said first metal is cobalt and said second metal is molybdenum. 